Thermal stratification test apparatus and method providing cyclical and steady-state stratified environments

ABSTRACT

A method and apparatus for a thermal stratification test providing cyclical and steady-state stratified environments. In order to test an electronic device, for example one having one or more levels of ball-grid-array interconnections, e.g., connecting a chip to a flip-chip substrate and connecting the flip-chip substrate to a printed circuit board of a device, an apparatus and method are provided to heat one side of the device while cooling the second side. In some embodiments, the process is then reversed to cool the first side and heat the second. Some embodiments repeat the cycle of heat-cool-heat-cool several times, and then perform functional tests of the electronic circuitry. In some embodiments, the functional tests are performed in one or more thermal-stratification configurations after cycling at more extreme thermal stratification setups. In some embodiments, a test that emphasizes solder creep is employed.

FIELD OF THE INVENTION

This invention relates to the field of electronic circuit testingdevices and methods, and more specifically to a method and apparatus fortesting circuits in cyclical and steady-state thermally stratifiedenvironments.

BACKGROUND OF THE INVENTION

Packaged electronic chips that are mounted on printed circuit boards(PCBs) typically need to be tested. Frequently, prior testing was doneat a wafer level after the chips have been largely fabricated, butbefore the chips are diced apart and packaged. Such a test is oftencalled a wafer test and sort operation, since good chips can be sortedfrom bad chips that fail the test, saving time and money since the badchips are discarded (or re-worked) before the effort of packaging thechips. Additional functional testing is often done after the chip isassembled to its first-level packaging, for example, when an integratedcircuit having solder-ball connections in a ball-grid array (BGA) isattached to a multiple-layer-ceramic (MLC) flip-chip substrate (FCsubstrate). Such an assembly often has larger solder-ball connectionsfor connecting to a PCB, and is called a FCBGA device. One or more suchdevices are mounted to a PCB to form a printed-board assembly (PBA).

There are failure modes of PBAs that are caused by or induced bydifferences in the respective coefficient of thermal expansion (CTE) ofthe various parts, e.g., of the silicon chip, the FC substrate, the PCB,and the solder-ball interconnections between various parts.

Conventional board-level test procedures sometimes include temperaturecycling wherein the printed circuit board and its components are placedwithin a chamber that can be heated or refrigerated. To test a design'scapability to withstand years of use, the temperature in the chamber iscycled from one extreme to another. Even so, some design flaws will notbe discovered. Undiscovered design errors can result in a substantialcapital cost to the chip and PBA manufacturer. Other testing needsinclude testing to verify the capabilities of new manufacturingprocesses (such as new solder compositions or new assembly processes) aswell as manufacturing stress testing to precipitate and detect latentdefects that were due to defective materials and/or manufacturingprocess errors.

What is needed is a fast, simple, inexpensive, reliable method andapparatus to test electronic chips and their connections to printedboard assemblies, so that the tester is compact and quickly detects manytemperature-dependent faults.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a graph 100 of thermal expansion vs. temperature for somematerials.

FIG. 2 is side schematic flowchart of a classical thermal cycling testprocedure 200.

FIG. 3 is side schematic flowchart of a TST (Thermal StratificationTest) procedure 300.

FIG. 4 is side view block diagram of TST system configuration 400.

FIG. 5 is side view block diagram of TST system configuration 500.

FIG. 6 is side view block diagram of TST system configuration 600.

FIG. 7 is a flowchart graph of a procedure 700 used with a TST system.

FIG. 8 is a flowchart graph of a procedure 800 used with a TST system.

FIG. 9 is schematic a thermal stratification test system 900.

FIG. 10 is side view block diagram of TST system configuration 1000.

FIG. 11 is side view block diagram of TST system configuration 1100.

FIG. 12 is side view block diagram of TST system configuration 1200.

FIG. 13 is side view block diagram of TST system configuration 1300.

FIG. 14 is side view block diagram of TST system configuration 1400.

FIG. 15 is a flowchart graph of a procedure 1500 used with a TST system900.

FIG. 16 is a flowchart graph of a procedure 1600 used with a TST system900.

FIG. 17 is side view block diagram of TST system configuration 1700.

FIG. 18 is side view block diagram of TST system configuration 1800.

FIG. 19 is schematic a thermal stratification test control system 1900.

FIG. 20 is schematic a chilling system 2000 used in some embodiments.

FIG. 21 is schematic a chilling system 2100 used in some embodiments.

DESCRIPTION OF PREFERRED EMBODIMENTS

In the following detailed description of the preferred embodiments,reference is made to the accompanying drawings that form a part hereof,and in which are shown by way of illustration specific embodiments inwhich the invention may be practiced. It is understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from the scope of the present invention.

The leading digit(s) of reference numbers appearing in the Figuresgenerally corresponds to the Figure number in which that component isfirst introduced, such that the same reference number is used throughoutto refer to an identical component which appears in multiple Figures.The same reference number or label may refer to signals and connections,and the actual meaning will be clear from its use in the context of thedescription.

Terminology

The terms chip, die, integrated circuit, monolithic device,semiconductor device, and microelectronic device, are usedinterchangeably in this description. The terms metal line, trace, wire,conductor, signal path and signaling medium are all related. The relatedterms listed above, are generally interchangeable, and appear in orderfrom specific to general. In this field, metal lines are sometimesreferred to as traces, wires, lines, interconnect or simply metal. Metallines, generally copper (Cu) or an alloy of Cu and another metal such asnickel (Ni), aluminum (Al), titanium (Ti), molybdenum (Mo), or stackedlayers of different metals, alloys or other combinations, are conductorsthat provide signal paths for coupling or interconnecting, electricalcircuitry. Conductors other than metal are available in microelectronicdevices. Materials such as doped polysilicon, doped single-crystalsilicon (often referred to simply as diffusion, regardless of whethersuch doping is achieved by thermal diffusion or ion implantation),titanium (Ti), molybdenum (Mo), and refractory metal suicides areexamples of other conductors.

In this description, the term metal applies both to substantially puresingle metallic elements and to alloys or combinations of two or moreelements, at least one of which is a metallic element. The term fluidincludes gasses (such as air) and liquids (such as Freon®, for example).

The term substrate generally refers to the physical object that is thebasic workpiece that is transformed by various process operations intothe desired microelectronic configuration. Substrates may includeconducting material (such as copper or aluminum), insulating material(such as sapphire, ceramic, fiber glass, or plastic), semiconductingmaterials (such as silicon), non-semiconducting, or combinations ofsemiconducting and non-semiconducting materials. In some embodiments,substrates include layered structures, such as a sheet of materialchosen for electrical and/or thermal conductivity (such as copper)covered with a layer of insulating material chosen for electricalinsulation, stability, and embossing characteristics.

The term vertical is defined to mean substantially perpendicular to themajor surface of a substrate. The terms height or depth refer to adistance in a direction perpendicular to the major surface of asubstrate.

Particularly with BGA connections, different amounts of heat-inducedexpansion (e.g., between the chip and the printed circuit it is attachedto using solder balls) can cause the solder-ball connections to fail (toopen). Defects in end-user PBAs are due to design error, material(component) variance, and/or assembly process variance. Defects relatedto design error are due to CTE mismatch. Defects related to materialvariance or process variance are not strictly due CTE mismatch. However,intermittent or latent defects related to material variance or assemblyprocess variance may be precipitated to hard failure via leveraging CTEvariance. Once precipitated via a process such as cyclical thermalstratification testing (cyclical TST is where opposite sides of the BGAconnections are alternately and repeatedly cycled hot/cold andcold/hot), these hard failures may be detected via a process such as asteady-state TST (a TST wherein opposite sides of the BGA connectionsare made hot/cold and functional electrical tests are performed).

FIG. 1 is a conceptual graph 100 of thermal expansion vs. temperaturefor some materials. The coefficient of thermal expansion differs forvarious materials, for example solder, FR4 substrate material, andsilicon (the substrate for integrated circuit chips). Thus, the lateraldimension versus temperature graph 110 for solder differs in slope fromthe lateral dimension versus temperature graph 120 for FR4 material, andfrom the lateral dimension versus temperature graph 130 for silicon.These differences in lateral dimension result in mechanical stress andstrain as a printed board assembly (PBA) experiences differenttemperatures.

FIG. 2 is side schematic flowchart of a classical thermal cycling testprocedure 200. At block 220 of procedure 200, the entire PBA (printedcircuit board assembly) 99 is placed in a chamber at room temperature(about 25 degrees Celsius). A first temperature transition 221 iseffected in the chamber and at block 230 the entire PBA 99, includingits chip 90, chip ball-grid-array interface 91, flip-chip (FC) substrate92, package ball-grid-array interface 93, and printed circuit board(PCB) 94, is made cold. That is, all portions of PBA 99 are surroundedby cold surfaces and/or a cold atmosphere that is, in some embodiments,stirred or blown in a turbulent flow to transfer that cold temperatureto PBA 99. A second temperature transition 222 is effected in thechamber, and at block 220, again the entire PBA 99 is brought to roomtemperature. That is, all portions of PBA 99 are surrounded by 25degrees Celsius surfaces and/or a 25 degrees Celsius atmosphere that is,in some embodiments, stirred or blown in a turbulent flow to transferthat 25 degrees Celsius temperature to PBA 99. In some embodiments,block 220 is merely a portion of the transition from block 230 to block210, wherein there is no attempt to hold at room temperature for anyamount of time (i.e., transition 222 and 212 are combined as a singletransition from cold to hot). A third temperature transition 212 iseffected in the chamber and at block 210; the entire PBA 99 is broughtto an elevated temperature (e.g., 50, 80 or 100 degrees Celsius). Afourth temperature transition 211 is effected in the chamber and atblock 220 the entire PBA 99 is again brought to room temperature. Insome embodiments, block 220 is merely a portion of the transition fromblock 210 to block 230, wherein there is no attempt to hold at roomtemperature for any amount of time (i.e., transition 211 and 221 arecombined as a single transition from hot to cold). In some embodiments,the transitions from hot to cold and back to hot are repeated aplurality of times.

At room temperature, in some embodiments, a nominal X distance 80between two contacts on chip 90 will equal the corresponding X distance81 between two corresponding contacts on the top of FC substrate 92, anda nominal X distance 82 between two contacts on PCB 94 will also equalthe corresponding X distance 81 between two corresponding contacts onthe bottom of FC substrate 92. (In some embodiments, the ball-to-balldistance and the ball size for interface 91 are different from theball-to-ball distance and the ball size for interface 93.) As PBA 99 iscooled, nominal distance 80 becomes shortened to cooled distance 83,nominal distance 81 is shortened to cooled distance 84, and nominaldistance 82 is shortened to cooled distance 85. Where the nominaldistances 80, 81, and 82 were equal, the cooled distances 83, 84, and 85are each different, due to the differing CTEs of the chip 90, FCsubstrate 92 and PCB 94. Similarly, as PBA 99 is heated, nominaldistance 80 is lengthened to heated distance 86, nominal distance 81 islengthened to heated distance 87, and nominal distance 82 is lengthenedto heated distance 88. Typically, distances 86, 87, and 88 are eachdifferent from each other and all are longer than the corresponding roomtemperature distances 80, 81, and 82. Since the heated X distances 86,87, and 88 seen for the chip 90, the FC substrate 92, and the PCB 94respectively, at block 210 are all longer than X distances 80, 81, and82 but slightly unequal one to the others, the mechanical stress isrelatively small, and numerous repetitions of the heating, cooling andreheating cycle are required in order to find problems in the PBA 99.

In some embodiments, functional testing, including applying electricalpower, providing stimulation signals, and then receiving and analyzingtest result signals, is performed at block 210, block 220, and/or block230.

FIG. 3 is side schematic flowchart of a thermal stratification testprocedure 300. Procedure 300 is similar to procedure 200, except thatrather than providing a uniform cold, room, or hot environment, athermally stratified cold-hot or hot-cold environment is provided at theextremes. At block 320 of procedure 300, similar to block 220 ofprocedure 200, the entire PBA 99 is placed in a chamber at roomtemperature (about 25 degrees Celsius). A first dual-temperaturetransition 321 is effected in the chamber (the top of the chamber ismade cold, and the bottom of the chamber is made hot) and, in someembodiments, at block 330 the top portion of PBA 99, including its chip90, chip ball-grid-array interface 91, and flip-chip (FC) substrate 92,is made cold, while printed circuit board (PCB) 94 is made hot, thusexacerbating the mechanical stress on package ball-grid-array interface93. That is, the top portions of PBA 99 are surrounded by cold surfacesand/or a cold atmosphere. In some embodiments, this atmosphere isstirred or blown in a turbulent flow to enhance a transfer of that coldtemperature to PBA 99. Simultaneously the bottom portions of PBA 99 aresurrounded by hot surfaces and/or a hot atmosphere, which, in someembodiments, is also stirred or blown. A second dual temperaturetransition 322 is effected in the chamber and at block 320; again theentire PBA 99 is brought to room temperature. That is, all portions ofPBA 99 are surrounded by 25 degrees Celsius surfaces and/or a 25 degreesCelsius atmosphere that is, in some embodiments, stirred or blown in aturbulent flow to transfer that 25 degrees Celsius temperature to PBA99. A third dual temperature transition 312 is effected in the chamberand at block 310 the top portion of PBA 99 is brought to an elevatedtemperature (e.g., 50, 80 or 100 degrees Celsius), while simultaneouslythe bottom portion of PBA 99 is chilled (e.g., 0, −10, or −40 degreesCelsius). A fourth dual temperature transition 311 is effected in thechamber and at block 320 the entire PBA 99 is again brought to roomtemperature.

In some embodiments, block 310 results in chip 90 having an expandeddimension 86 for chip 90 and an expanded distance 87 for FC substrate92, but a contracted distance 85 for PCB 94, thus there is more stresson BGA interface 93 than in either block 210 or block 230 of FIG. 2.Similarly, block 330 results in chip 90 having a contracted dimension 83for chip 90 and a contracted distance 84 for FC substrate 92, but anexpanded distance 88 for PCB 94, so there also is more stress on BGAinterface 93 at block 330 than in either block 210 or block 230 of FIG.2.

In some embodiments, transitions 311 and 321 are combined as a singletransition from block 310 to block 330, transitions 322 and 312 arecombined as a single transition from block 330 to block 310, and theroom temperature state represented by block 320 is merely a point alongthe transitions. In other embodiments, the transition 313 from the topbeing hot to the top being cold occurs at a different time (eitherbefore or after) the transition 314 from the bottom being cold to thebottom being hot. In some embodiments, the transition 315 from the topbeing cold to the top being hot occurs at a different time (eitherbefore or after) the transition 316 from the bottom being hot to thebottom being cold.

In some embodiments, a confinement mechanism or cell shroud is providedso that the top chamber primarily cools/heats only chip 90 using forcedturbulent air, and the bottom portions that are heated/cooled includeboth PCB 94 and FC substrate 92. In other embodiments, such as shown inFIG. 10, the top forcing unit only heats/cools chip 90 using a contactsurface, while the lower thermal forcing unit only cools/heats PCB 94and FC substrate 92. In yet other embodiments, various subportions ofthe top and bottom are connected to the thermal forcing units, such asshown in FIG. 12, for example.

In some embodiments, functional testing, including applying electricalpower, providing stimulation signals, and then receiving and analyzingtest result signals, is performed at block 310, block 320, and/or block330.

FIG. 4 is side view block diagram of thermal stratification test (TST)system configuration 400 used in some embodiments. Configuration 400includes a thermal unit 410 having a thermal forcing unit (TFU) 411 forthe top chamber 421 and a thermal forcing unit (TFU) 412 for the bottomchamber 422 of thermal station 420. In some embodiments, a fan 415 orother circulating device stirs or blows the fluid (e.g., air or othersuitable inert or electrically non-conductive fluid) in a turbulent flow426 at a temperature T_(TOP), and a fan 416 or other circulating devicestirs or blows the fluid (e.g., also air or other suitable inert orelectrically non-conductive fluid) in a turbulent flow 427 at atemperature T_(BOTTOM). In some embodiments, PBA 99 is placed on a rim425 (e.g., in some embodiments, either covered with or entirely made ofa compliant material that forms a seal between upper chamber 421 andlower chamber 422). In some embodiments, enough heat or cold is suppliedby the thermal forcing units 411 and 412 that small leaks around sealrim 425 (and/or through vias and other holes in PCB 94) do notsignificantly affect the desired heating and cooling effects. Asdescribed above, in some embodiments, PBA 99 includes a PCB 94, an FCsubstrate 92, a chip 90, a solder-ball interface 93 connecting PCB 94 toFC substrate 92, and a solder-ball interface 91 connecting FC substrate92 to chip 90.

In the embodiment shown, the highest stress is expected on interface 93,since when TFU 412 is forcing cold and TFU 411 is forcing heat (andassuming positive CTE values), PCB 94 will contract and FC substrate 92will expand (or not contract as much), and FC substrate 92 and chip 90will both expand, although by different amounts typically (or FCsubstrate 92 will contract and chip 90 will expand), resulting in asmaller stress at interface 91.

In an operational real-use environment, the chip 90 is typically thesource of heat and the FC substrate is somewhat cooler, and PCB 94 iseven cooler, and the TST (thermal stratification test) configurationemulates such a condition better than thermal tests that heat or coolall layers to about the same temperature. The TST configuration canproduce stresses similar in nature to the use environment, but larger inmagnitude therefore achieving test acceleration (test time compression.)

FIG. 5 is side view block diagram of thermal stratification systemconfiguration 500 used in one embodiment. Configuration 500 includes athermal station 520 having an upper chamber 521 driven by a thermalforcing unit (TFU) 411 of thermal unit 510 as in FIG. 4; however, thisembodiment uses a heating/cooling plate 529 and a compliant thermallyconductive and electrically insulating pad 528 to form the lower“chamber” 522 across substantially all of PCB 92. This lower chamber 522is thermally powered by coolant chiller/heater driver 512 throughcable/conduit 517. In some embodiments, heating/cooling plate 529 useschannels to circulate a cooling fluid (such as, for example, afluorocarbon, ammonia, ethylene glycol or alcohol) during its coolingcycle, and electrical resistance coils (such as Nichrome) for itsheating cycle. In other embodiments, a Peltier device (such as shown inFIG. 10) that heats and cools dependent on the direction of current flowis used in place of plate 529. In some embodiments, a heating/coolingplate similar to plate 529 is also used in place of upper chamber 521 aswell. In some embodiments, an insulating mask pad 525 is laid overportions of PCB 94, in order to limit the heating and cooling to theportions of interest, e.g., solder balls 91 and solder balls 93 and thesurfaces interfacing to them.

FIG. 6 is side view block diagram of thermal stratification systemconfiguration 600 used in some embodiments. Configuration 600 includes athermal station 620 having an upper chamber 621 driven by a thermalforcing unit (TFU) 411 of thermal unit 610 as in FIG. 4, however, thisembodiment has chamber 621 surrounding both the top and bottom of PCB 94at its periphery, and uses a heating/cooling plate 629 and a compliantthermally conductive and electrically insulating pad 628 to form thelower “chamber” 622 across only that portion of PCB 92 that is under FCsubstrate 92. This small portion of lower chamber 622 is thermallypowered by coolant chiller/heater driver 612 through cable/conduit 617(much like plate 529 of FIG. 5), but the rest of lower chamber 622 hascirculating fluid from the top chamber 621. In other embodiments, aPeltier device that heats and cools dependent on the direction ofcurrent flow is used in place of plate 629. In some embodiments, aheating/cooling plate similar to plate 529 of FIG. 5 is used in place ofupper chamber 621 across substantially all of PBA 99, as well.

FIG. 7 is a flowchart graph of a procedure 700 used with a thermalstratification system 900 (see FIG. 9) in some embodiments. Graph line721 is a plot of temperature vs. time for the top chamber or plate (forFIGS. 4–6, 9–12, 14, 17 and 18), and graph line 722 is a plot oftemperature vs. time for the bottom chamber or plate (for FIGS. 4–6,9–12, 14, 17 and 18). The temperature for graph line 721 alternatesbetween a maximum precipitation temperature Tpmax 731 and a minimumprecipitation temperature Tpmin 733, while the temperature for graphline 722 alternates between Tpmin 733 and Tpmax 731, each simultaneouslyswitching to the opposite temperature extreme from the other. In someembodiments, about twelve temperature cycles are used, but in otherembodiments, other numbers of cycles are used.

In some embodiments, graph line 740 represents when electricalfunctional tests are performed (up representing tests being performed,and down representing idle periods). Functional test 741 is performed atroom temperature (top and bottom) before temperature cycling isperformed, to check that the device is initially functional. Functionaltest 742 is performed at room temperature (top and bottom) aftertemperature cycling is performed, to check that the device is functionalafter temperature cycling. Functional tests 743 and 744 are performed ata minimum detection temperature Tdmin (top and bottom in this embodimentbeing at temperature 733) after temperature cycling is performed, tocheck that the device is functional in a cold environment aftertemperature cycling. Functional tests 745 and 746 are performed at amaximum detection temperature Tdmax (top and bottom, in this embodimentbeing at temperature 731) after temperature cycling is performed, tocheck that the device is functional in a hot environment aftertemperature cycling.

In some embodiments, functional test 747 is performed at roomtemperature (top and bottom) after temperature cycling is performed, tocheck that the device is functional after temperature cycling. In someembodiments, the functional tests 742–747 are performed in the ordershown, but in other embodiments, other orders are used. In otherembodiments, at least some of the functional tests are performed understeady-state thermal-stratification-test conditions (e.g., 842 and 843of FIG. 8), wherein at least some of the functional tests are performedduring the times when the top and bottom temperatures are out-of-phase(i.e., either the device's top is hot and its bottom is cold as infunctional test 842, or the top is cold and bottom is hot whilefunctional test 843 is performed). One advantage of performing thisthermally out-of-phase functional test is to mechanically “load” the PBAinterfaces with additional stresses above and beyond those obtainedunder conventional uniformly hot/cold functional testing. The additionalmechanical loading of the interfaces makes precipitation and detectionof intermittent solder joint defects such as solder ball microcracksmore probable, by forcing an intermittent connection to stay open whilefunctional test (error detection) is performed (i.e., testing aconnection that would open only under thermal stratification (a hot/coldor cold/hot temperature condition), but which would close again oncethermal equivalence (i.e., a hot/hot, cold/cold, or room/roomtemperature condition) was restored).

Note that microcracks parallel to the plane of the PCB (i.e., cracks inthe solder ball that are parallel to the face of the PCB) are often themost troublesome form of solder defect to detect in a manufacturingenvironment, since the crack in the connection can close when thetemperature stress is removed or changed. In some embodiments,steady-state TST is able to fill this gap in conventional PBAmanufacturing test technology (since thermal stratification can holdsuch cracks open during the functional test); hence, it provides highvalue. Further, one advantage of cyclical TST combined with steady-stateTST is that cyclical TST precipitates many marginal or partial defectsto full defects. Then, steady-state TST detects these precipitateddefects. These defects would have been previously undetectable usingconventional methods.

In some embodiments, Tpmax is equal to Tdmax and Tpmin is equal toTdmin, but in other embodiments, Tdmax is different from Tpmax (such asshown in FIG. 8), and Tdmin is different from Tpmin. In someembodiments, the Tpmax for both T_(TOP) and T_(BOTTOM) are the same asshown, while in other embodiments, the Tpmax for the top chamber orplate is different than the Tpmax used for the bottom chamber or plate.Similar rules apply for the Tpmin and Tdmin values of T_(TOP) andT_(BOTTOM) chamber temperatures.

FIG. 8 is a flowchart graph of a procedure 800 used with a thermalstratification system 900 (see FIG. 9) in some embodiments. In someembodiments, the temperature cycling for procedure 800 is much the sameas for procedure 700 of FIG. 7, however the Tpmax 831 is hotter thanTdmax 832 for the top side, Tpmax 851 is hotter than Tdmax 852 for thebottom side, Tpmin 834 is colder than the Tdmin 833 for the top side,and the Tpmin 854 is colder than the Tdmin 853 for the bottom side. Insome embodiments, the maximum and minimum temperatures for top andbottom are the same respective temperatures (i.e., Tpmax 831=Tpmax 851,Tdmax 832=Tdmax 852, Tdmin 833=Tdmin 853, and Tpmin 834=Tpmin 854),while in other embodiments, different maximum and minimum temperaturesare used for top and bottom. Graph line 821 represents that temperatureversus time plot for the top chamber (e.g., chamber 421 of FIG. 4), andgraph line 822 represents that temperature versus time plot for thebottom chamber (e.g., chamber 422 of FIG. 4).

In some embodiments, functional testing is performed during steady-statethermal stratification (also called “steady-state TST”), i.e.,functional testing while the T_(TOP) and T_(BOTTOM) are maintained atTdmin/Tdmax out of phase (either hot/cold as in test 842 or cold/hot asin test 843 of FIG. 8). In some embodiments, a steady-state functionalTST is performed alone (i.e., without previously performing thermalcycling), and in other embodiments, a cyclic TST (i.e., thermalstratification cyclically alternated to precipitate a failure mode) isperformed, followed by a steady-state TST (functional testing performedwhile the device is held in thermal stratification)

In some embodiments, graph line 840 represents when electricalfunctional tests are performed. Functional test 841 is performed at roomtemperature (in both top and bottom chambers) before temperature cyclingis performed, to check that the device is initially functional. In someembodiments, functional test 842 is performed at Tdmax temperature forthe top chamber (e.g., 421 of FIG. 4) and Tdmin temperature for thebottom chamber (e.g., 422 of FIG. 4) after temperature cycling isperformed, to check that the device is functional (in a hot/coldconfiguration) after temperature cycling. Functional test 843 isperformed at Tdmin temperature for the top chamber (e.g., 421 of FIG. 4)and Tdmax temperature for the bottom chamber (e.g., 422 of FIG. 4) aftertemperature cycling is performed, to check that the device is functional(in a cold/hot configuration), called thermal stratification functionaltesting, after temperature cycling. Functional tests 844 and 845 areperformed at a minimum detection temperature Tdmin 833 (top and bottom)after temperature cycling is performed, to check that the device isfunctional in a cold/cold environment after temperature cycling.Functional tests 846 and 847 are performed at a maximum detectiontemperature Tdmax (top and bottom) after temperature cycling isperformed, to check that the device is functional in a hot/hotenvironment after temperature cycling. Functional test 848 is performedat room temperature (top and bottom) after temperature cycling isperformed, to check that the device is functional after temperaturecycling. In some embodiments, the functional tests 842–848 are performedin the order shown, but in other embodiments, other orders are used.

FIG. 9 is schematic a thermal stratification test system 900 used insome embodiments. System 900 includes a testing controller orinformation processing system (IPS) 940 (such as a programmablecomputer, or a hardwired logic circuit) that controls the top thermalunit 911 and the bottom thermal unit 912 of thermal controller 910. IPS940 is also operative coupled to electrical connector 930 to transmitpower and stimulation signals and/or clocks and to receive test resultssignals to one or more of the devices under test (DUTs) (e.g., PBA 99)carried on conveyer system 950. In some embodiments, conveyer 950 (e.g.,a belt 952 having holes 953 and running around motorized rollers 951that are controlled by ISP 940 via conveyor/sort program 943) moves aseries of DUTs 99 one after another to thermal/functional station (TFS)920. In other embodiments, each PBA 99 is manually loaded into TFS 920.In some embodiments, TFS 920 includes upper chamber 921 and lowerchamber 922 such as shown as thermal stations 420 of FIG. 4, 520 of FIG.5, 620 of FIG. 6, 1020 of FIG. 10, 1120 of FIG. 11, or 1220 of FIG. 12.In some embodiments, once a PBA 99 is moved in place at station 920, arobotic actuator 929 move the top unit 921 down and the bottom unit 922up into place around the selected PBA 99. Thermal program 941 thencontrols the thermal cycling as described for FIGS. 7 and 8 above.Functional program 942 controls the transmitting (as described in FIGS.7 and 8) of power and stimulation signals and/or clocks and thereception of test results signals through electrical connector 930connected to connector 97 on the selected PBA 99. In some embodiments,robotic sorting of the PBAs based on the functional test results iscontrolled by convey/sort program 943. In some embodiments, the softwarefor thermal program 941, functional program 942, and/or convey/sortprogram 943 is obtained on computer-readable media 946 (such as adiskette, CDROM, or an internet download connection) that is connectedto a suitable input device 945 and then optionally stored to storage944. Some embodiments substitute manual processes for one or moreoperations described above.

FIG. 10 is side view block diagram of a thermal stratification systemconfiguration 1000 used in some embodiments. In the embodiment shown,Peltier device 1027 heats and cools only chip 90 as controlled by upperthermal unit 1011 of thermal controller 1010, while Peltier devices1025, 1029, and 629 cool and heat the outer portions of FC substrate 92and PCB 94. Configuration 1000 places the highest mechanical stress oninterface 91 rather than interface 93, as was the case for FIGS. 4–6.Compliant pads 1024, 1026, 1028 and 628 are thermally conductive andelectrically insulating.

FIG. 11 is side view block diagram of a thermal stratification systemconfiguration 1100 used in some embodiments. Configuration 1100 is thesame as configuration 400 of FIG. 4, except that the thermal chamber1120 includes a cup-like upper chamber 1123 having a compliant lip 1125that presses against FC substrate 92 to enclose a chamber 1121 in placeof the upper chamber 421 of FIG. 4. Similarly, a cup-like lower chamber1124 having a compliant lip 1126 that presses against PCB 94 around anarea corresponding to the perimeter of FC substrate 92 to enclose achamber 1122 in place of the lower chamber 422 of FIG. 4. In someembodiments, the upper chamber 1123 is placed against the perimeter ofonly chip 90 (in some embodiments, against the top surface, and in otherembodiments, along the sides of chip 90 but against FC substrate 92 toenclose substantially only chip 90), in order that the greatest thermaldifference and thus the highest mechanical stress is on interface 91rather than interface 93, as was the case for FIGS. 4–6.

FIG. 12 is side view block diagram of a thermal stratification systemconfiguration 1200 used in some embodiments. In this embodiment, thermalforcing unit (TFU) 411 controls the upper left chamber 1221 of TSTstation 1220, TFU 1212 controls the lower right chamber 1224, whilethermal forcing unit 412 controls the lower left chamber 1222 and TFU1211 controls the upper right chamber 1223. Configuration 1200 providesa thermal stratification top-to-bottom (T1 to T2 ) by the temperaturedifference between chamber 1221 and 1222 (as well as T2 to T1 between1223 and 1224), and a left-to-right thermal stratification by thetemperature difference between chamber 1221 and 1223 (as well as between1222 and 1224). In some embodiments, the dividing wall 1228 betweenchambers 1221 and 1223 is pressed down the middle of chip 90 to inducestresses there. In some embodiments, a solely left-to-right thermalstratification is achieved by connecting chambers 1221 and 1222 tothermal forcing unit 411 and connecting chambers 1223 and 1224 tothermal forcing unit 412. Still other embodiments include only the toptwo chambers 1221 and 1223 connected to the thermal forcing units asshown, and omitting the lower chambers 1222 and 1224, in order to haveonly left-to-right thermal stratification on chip 90 and FC substrate92.

FIG. 13 is side view block diagram of a thermal stratification systemconfiguration 1300 used in some embodiments. In some embodiments, hotthermal unit 1311 controls the upper left chamber of source plenum 1321and collection enclosure 1326 and the lower right chamber of sourceplenum 1324 and collection enclosure 1329, while in other embodimentssuch as the embodiment shown, a separate hot thermal unit 1314 controlsthe lower right chamber of plenum 1324. In some embodiments, coldthermal unit 1312 controls the upper right chamber of source plenum 1323and collection enclosure 1328 and the lower left chamber of sourceplenum 1322 and collection enclosure 1327, while in other embodimentssuch as the embodiment shown, a separate cold thermal unit 1313 controlsthe upper left chamber of plenum 1323. Actuator 1330 is attached tograsper 1331, which in turn holds PCB 94. In the embodiment shown, chip90 is directly attached to PCB 94. Actuator 1330 moves PCB 94 toalternately move chip 90 from station A (hot on top and cold on bottomusing the chambers of enclosures 1326 and 1327 respectively) to stationB (cold on top and hot on bottom using the chambers of enclosures 1328and 1329 respectively). In some embodiments, the hot thermal unit 1311and the cold thermal unit 1312 are turned off when the chip 90 is instation B as shown (no heating or cooling provided at station A), andonly cold thermal unit 1313 and hot thermal unit 1314 are activated.Then, the hot thermal unit 1311 and the cold thermal unit 1312 areactivated when the chip 90 is in station A (actuator 1330 having pulledPCB 94 to the left, and cold thermal unit 1313 and hot thermal unit 1314are turned off (no heating or cooling provided at station B).Configuration 1300 can alternatively provide a top-to-bottom thermalstratification by the temperature difference between chamber 1321 and1322 (as well as between 1323 and 1324), and a left-to-right thermalstratification by the temperature difference between chambers 1321 and1323 (as well as between 1322 and 1324) as shown in FIG. 12. In otherembodiments, further chambers are provided besides those shown, in orderto provide a hot top and hot bottom, or a cold top and cold bottom, or aroom temperature top and room temperature bottom chambers.

FIG. 14 is side view block diagram of a thermal stratification systemconfiguration 1400 used in some embodiments. System configuration 1400includes a series of hot/cold, cold/hot, hot/hot, cold/cold, and/orroom/room temperature stratification stations or cells through which thedevice under test (DUT) is sequentially passed. System 1400 allows rapidsequential processing of a single PBA 99 or a plurality of PBAs 99 oneafter another. Thus, hot/cold station A is hot on the top via chamber1421A and cold on the bottom via chamber 1422A. Similarly, cold/hotstation B uses chambers 1421B and 1422B; hot/cold station C useschambers 1421C and 1422C; and cold/hot station D uses chambers 1421D and1422D. In various different embodiments, a chosen number and size ofchambers are provided to meet design and testing needs. In someembodiments, just two cells are provided (or any other suitable numberand configuration of cells), a hot/cold cell and a cold/hot cell, andconveyor section 952 is reversible to allow a PBA or a portion thereofto be repeatedly cycled back and forth between them. In someembodiments, cold/cold station E uses chambers 1421E and 1422E; hot/hotstation F uses chambers 1421F and 1422F; and hot/hot station G useschambers 1421G and 1422G. In some embodiments, all of the hot chambersare supplied with blown hot air from hot thermal unit 1411, and all ofthe cold chambers are supplied with blown cold air from cold thermalunit 1412. Adjusting or setting the sizes of the individual cells, thenumber of cells, and the speed of the conveyor 950 determines the shapeof the graph of temperature stratifications. In some embodiments,conveyor 950, which runs around rollers 951 (some of which aremotorized, in some embodiments) includes a plurality of sections 952 and953 that are run at different speeds, so that the time per cell can befurther varied for the different sections.

In some embodiments, IPS testing computer 940 includes a functionalprogram 942 that controls the transmitting (as described in FIGS. 7 and8) of power and stimulation signals and/or clocks and the reception oftest results signals through electrical connector 930 connected toconnector 97 on the selected PBA 99. In some embodiments, functionaltesting occurs only in cold/cold cell E, hot/cold cell F, and hot/hotcell G, as well as at room temperature. In other embodiments, functionalsteady-state thermal-stratification functional testing is performed inone or more other TST (thermal stratification test) cells such as cellsA through D.

In some embodiments, TST is used to test chip packaging as describedabove. In various other embodiments, thermally stratified cycling andsteady-state thermally stratified functional testing is performed duringtesting of some or all of the following features of computer systems:probe heads, manual cable or card insertion, automated cable or cardinsertion, host personal computer assist, diagnostic software,data-collection systems, etc.

FIG. 15 is a flowchart graph of a procedure 1500 used with a thermalstratification system 900 (see FIG. 9) in some embodiments, particularlyto perform longer-term reliability testing, and/or particularly to testfor solder-creep problems. In some embodiments, the temperature cyclingfor procedure 1500 is much the same as for procedure 700 of FIG. 7 andprocedure 800 of FIG. 8, however for a plurality of the test cycles bothsides of the device (e.g., top and bottom) are brought to Tpmax 831 and851, respectively, just before taking one side or the other to Tpmin 834or 854, respectively. Graph line 1521 represents that temperature versustime plot for the top chamber (e.g., chamber 921 of FIG. 9), and graphline 1522 represents that temperature versus time plot for the bottomchamber (e.g., chamber 922 of FIG. 9). Thus, with both sides at theirrespective Tpmax 831 and 851, the hot solder is given time (e.g., aboutten minutes for each solder creep period 1510, in some embodiments) tocreep to a relaxed configuration and then rather suddenly, the bottomside is cooled Tpmin 854, thus placing additional mechanical stress onthe solder-ball joints. In some embodiments, a large number oftemperature fluctuations are performed (e.g., days or weeks of testingof a repeated series of cycles).

In some embodiments, functional testing is performed during steady-statethermal stratification (also called “steady-state TST”), i.e.,functional testing while the T_(TOP) and T_(BOTTOM) are maintained atTdmin/Tdmax out of phase, at the end of the extended period oftemperature cycles.

FIG. 16 is a flowchart graph of a procedure 1600 used with a thermalstratification system 900 (see FIG. 9) in some embodiments, alsoparticularly to perform longer-term reliability testing, and/orparticularly to test for solder-creep problems. Graph line 1621represents that temperature versus time plot for the top chamber (e.g.,chamber 921 of FIG. 9), and graph line 1622 represents that temperatureversus time plot for the bottom chamber (e.g., chamber 922 of FIG. 9).Thus, with both sides at their respective Tpmax 831 and 851, the hotsolder is given time (e.g., about ten minutes for each solder creepperiod 1510, in some embodiments) to creep to a relaxed configurationand then rather suddenly, the bottom side is cooled Tpmin 854 (afterperiods 1611, 1613, and 1615), and after alternate periods 1612 and 1614the top side is cooled to Tpmin 834, thus placing additional alternatingmechanical stress on the solder-ball joints. Again, in some embodiments,a large number of temperature fluctuations are performed (e.g., days orweeks of testing of a repeated series of cycles).

FIG. 17 is side view block diagram of a thermal stratification systemconfiguration 1700 used in some embodiments. In this embodiment, thermalforcing unit (TFU) 411 controls the upper left chamber 1721 of TSTstation 1220, TFU 1742 controls the lower right thermal plate 1724,while thermal forcing unit 1241 controls the lower thermal plate 1722and TFU 1211 controls the upper right chamber 1723. Configuration 1700provides a thermal stratification top-to-bottom (T1 to T2 ) by thetemperature difference between chamber 1721 and plate 1722 (as well asT2 to T1 between chamber 1723 and plate 1724), and a left-to-rightthermal stratification by the temperature difference between chambers1721 and 1723 (as well as between plates 1722 and 1724). In someembodiments, the dividing wall 1728 between chambers 1221 and 1223includes selectively operable cross ventilation fans 1716 and 1717 usedto exchange air during the transitions from hot-cold to cold-hot inorder to improve temperature change efficiency. In some embodiments, theoperation of system configuration 1700 is the same as for configuration1200 of FIG. 12. In some embodiments, separate PBAs 99 are placed in theleft and right chambers. In other embodiments, a single PBA 99 havingtwo portions of interest is place in both chambers, such that oneportion of interest is in the left chamber and the other is in the rightchamber.

FIG. 18 is side view block diagram of thermal stratification systemconfiguration 1800 used in one embodiment. Configuration 1800 includes athermal station 1820 having an upper chamber 1821 driven by a thermalforcing unit (TFU) 411 as in FIG. 5 and a heating/cooling plate 529 anda compliant thermally conductive and electrically insulating pad 528 toform the lower “chamber” 522 across substantially all of PCB 94. Thislower chamber 522 is thermally powered by coolant chiller/heater driver512 through cable/conduit 517. Operation is the same as for FIG. 5. Insome embodiments, a thermally insulating mask pad 1825 having aplurality of openings is laid over portions of PCB 94, in order to limitthe heating and cooling to the portions of interest, e.g., the pluralityof chips 90, and the solder balls 91 and solder balls 93 and thesurfaces interfacing to them. In some embodiments, a radiant heater 1860is provided to supplement the heating of chips 90, and in some suchembodiments, the top surface of insulating pad 1825 is made reflective(e.g., with a foil top surface). In these embodiments, the thermalstratification is concentrated to mostly affect the chips 90 and thePCBs 92 and the solder balls 91 and 93, while having less effect on therest of PBA 99

FIG. 19 is schematic a thermal stratification test control system 1900used in one embodiment. System 1900 includes a thermal station 1920having a thermal plate 1930 (in a configuration as would be used in FIG.5). System 1900 includes a liquid chiller/recirculator/reservoir system1910 which pumps out 1914 chilled liquid (e.g., at −20 degrees C.).Plate temperature controller 1940 (in some embodiments, such as made byOmron or Watlow) provides “cool-ON” control signal 1943, which controlsvalve 1917 to either path 1913 through plate 1930, or to bypass loop1918. In some embodiments, valve 1917 is an either-or valve, while inother embodiments, a proportional valve is used. Communications port1915 (in some embodiments, using RS 485 protocol) allows control signalsto control the operation of system 1910, and AC power 1919 provideschiller/recirculator power. The liquid that passes through path 1913goes through thermal plate 1930 (in some embodiments, made of copperand/or aluminum) to cool it, and then returns by path 1936 to junction1916, where it joins with liquid from bypass loop 1918 and goes by path1937 back to system 1910. In some embodiments, plate temperaturecontroller 1940 also provides “heat-ON” control signal 1942, whichcontrols electrical switch 1947, which controls whether or not (or howmuch) power from source 1949 (passing through fuse 1948) is applied toresistance heaters 1933 (in some embodiments, embedded cartridge heaterssuch as Watlow FIRERODs, from Watlow Electric Manufacturing are used).In some embodiments, communications port 1945 (in some embodiments,using RS 485 protocol) allows control signals to control the operationof plate temperature controller 1940. In some embodiments, control ofthe temperature and circulation of upper chamber 1921 is conventionalsuch as used in an Espec thermal chamber (e.g., from ESPEC NORTHAMERICA, INC.).

FIG. 20 is schematic a chilling system 2000 used in some embodiments,wherein system 1910A is used for chilling system 1910 of FIG. 19. System1910A includes a multistage series of thermoelectric chillers tosuccessively lower the temperature of the circulating chilled liquids.In some embodiments, an air-liquid thermoelectric chiller 2010 provideschilled liquid at about +10 C. to +5 C. to the high side ofliquid-liquid thermoelectric chiller 2020, which provides chilled liquidat about +0 C. to −10 C. to the high side of liquid-liquidthermoelectric chiller 2030, which provides chilled liquid at about −10C. to −20 C., which is then accumulated in chilled liquid reservoir2040, and supplied as needed to plate 1930 as controlled by controller1940 as described for FIG. 19 above.

FIG. 21 is schematic a chilling system 2100 used in some embodiments,wherein system 1910B is used for chilling system 1910 of FIG. 19. System1910B includes a single stage mechanical chiller to lower thetemperature of the circulating chilled liquid. In some embodiments, anair-liquid mechanical chiller 2110 provides chilled liquid at about −10C. to −20 C., which is then accumulated in chilled liquid reservoir2040, and supplied as needed to plate 1930 as controlled by controller1940 as described for FIG. 19 above.

In some embodiments, chip 90 and/or other components are self-heated byapplying power and/or switching signals, in order to supplement orreplace the devices and methods for providing heating as describedabove.

In some embodiments, a thermal mask (e.g., a thermally insulating padhaving one or more holes for the component(s) to which heat and cold areto be applied) is provided to help achieve thermal isolation of somecomponents on the primary (e.g., top) side of PCB 94.

In some embodiments, chip-scale packages (e.g., a BGA chip 90 mounteddirectly onto PCB 94 without an intervening FC substrate 92) are testedusing the above methods and apparatus of the invention.

Note that other embodiments include pins on FC substrate 92 to connectto PCB 94, or to a socket (such as a zero-insertion-force (ZIF) socket)soldered to PCB 94. Still other embodiments include other connectionmeans for connecting chip 90 to substrate 92, such as flying wire bonds.Thus, the TST described above is not limited to only chips with BGAsolder balls and FC substrates with BGA solder balls, but is widelyapplicable to many situations where it may be desirable to perform athermal stratification test and/or thermal cycling and functionaltesting.

One embodiment of the present invention includes an apparatus thatincludes a first heat-transfer device (e.g., thermal forcing unit 411and chamber 421 of FIG. 4, and similar combinations in FIGS. 5, 6, 9,10, 11, and 12) for changing a temperature of a first surface of anelectronic device, a second heat-transfer device (e.g., thermal forcingunit 412 and chamber 422 of FIG. 4, and similar combinations in FIGS. 5,6, 9, 10, 11, and 12) for changing a temperature of a second surface ofthe electronic device opposite the first surface, a controller (e.g.,410 of FIG. 4 or program 941 of FIG. 9) operatively coupled to the firstheat-transfer device and to the second heat-transfer device and operableduring a first period of time to cause the first heat-transfer device toraise the temperature of the first surface and the second heat-transferdevice to lower the temperature of the second surface to a level belowthe temperature of the first surface, and operable during a secondperiod of time to cause the first heat-transfer device to lower thetemperature of the first surface and the second heat-transfer device toraise the temperature of the second surface to a level above thetemperature of the first surface of the electronic device.

Some embodiments further include a system 900 that includes a probe head920 that includes one or more of the configurations 400, 500, 600, 1000,1100, 1200, 1300, 1400, 1700, 1800 described above, the system 900further comprising one or more information-processing systems 940 thatcollect testing results from the electronic device after the secondperiod of time, and based on the testing results, sort the electronicdevice as good or faulty. In other embodiments, functional testing isperformed during testing of some or all of the following features: probehead, manual cable or card insertion, automated cable or card insertion,host PC assist, diagnostic SW, data collection systems, etc.

In some embodiments, the first heat-transfer device includes a chamber(e.g., 421, 521, 621, or 1121) that substantially surrounds the firstsurface of the electronic device and circulates a heated fluid againstthe first surface of the electronic device during the first period oftime.

In some embodiments, the second heat-transfer device includes a chamber(e.g., 422 or 1122) that substantially surrounds the second surface ofthe electronic device and circulates a cooled fluid against the secondsurface of the electronic device during the first period of time.

In some embodiments, the first surface includes substantially all of oneside of a printed circuit board, and the second surface includessubstantially all of the opposite side of the printed circuit board.

In some embodiments, the first surface includes substantially all of oneside of a printed circuit board, and the second surface includes asubstantially smaller portion of the opposite side of the printedcircuit board corresponding to a single integrated circuit packagemounted on the electronic device.

In some embodiments, the second heat-transfer device includes athermally conductive surface that is pressed against the second surfaceof the electronic device and is cooled during the first period of time.

In some embodiments, the first surface includes substantially all of oneside of a printed circuit board, and the second surface includessubstantially all of the opposite side of the printed circuit board. Insome such embodiments, the first surface includes substantially all ofone side of a printed circuit board, and the second surface includes asubstantially smaller portion of the opposite side of the printedcircuit board corresponding to a single integrated circuit packagemounted on the electronic device.

In some embodiments, the first heat-transfer device includes a thermallyconductive surface that is pressed against the first surface of theelectronic device and is heated during the first period of time.

In some embodiments, the first heat-transfer device includes a Peltierdevice, and has a compliant material between the Peltier device and thefirst surface of the electronic device.

In some embodiments, the second heat-transfer device includes athermally conductive surface that is pressed against the second surfaceof the electronic device and is cooled during the first period of time.

In some embodiments, the second heat-transfer device includes a Peltierdevice, and has a compliant material between the Peltier device and thesecond surface of the electronic device.

In some embodiments, the first heat-transfer device includes a chamberthat substantially surrounds the first surface of the electronic deviceand circulates a heated fluid against the first surface of theelectronic device during the first period of time, the secondheat-transfer device includes a chamber that substantially surrounds thesecond surface of the electronic device and circulates a cooled fluidagainst the second surface of the electronic device during the firstperiod of time, the first surface includes substantially only a portionof one side of a printed circuit board corresponding to a singleintegrated circuit package mounted on the electronic device, and thesecond surface includes substantially only a portion of the oppositeside of the printed circuit board corresponding to the single integratedcircuit package.

One embodiment of the present invention includes a method for performingthermal-stress testing. This method includes providing an electronicdevice, and during a first period of time, heating a first side of theelectronic device and simultaneously cooling a second side of the deviceopposite the first surface to create a thermal stratification profile,and performing a functional electronic test of an integrated circuit onthe electronic device. Some embodiments earlier include heating bothsides to induce solder creep.

Some embodiments of the method further include, during a second periodof time subsequent to the first period of time, cooling the first sideof the electronic device and simultaneously heating the second side ofthe electronic device.

Some embodiments of the method further include, during a second periodof time subsequent to the first period of time, cooling the first sideof the electronic device and simultaneously heating the second side ofthe electronic device, during a third period of time subsequent to thesecond period of time, heating the first side of the electronic deviceand simultaneously cooling the second side of the electronic deviceopposite the first surface, and during a fourth period of timesubsequent to the third period of time, cooling the first side of theelectronic device and simultaneously heating the second side of theelectronic device.

Some embodiments of the method further include, during a fifth period oftime subsequent to the fourth period of time, causing the temperature ofboth the first side and the second side of the electronic device to beapproximately 25 degrees Celsius, and performing a functional electronictest of an integrated circuit on the electronic device at this roomtemperature.

Some embodiments of the method further include, during sixth a period oftime subsequent to the fourth period of time, causing the temperature ofboth the first side and the second side of the electronic device to becooled substantially below 25 degrees Celsius, and performing afunctional electronic test of the integrated circuit at this loweredtemperature.

Some embodiments of the method further include, during seventh a periodof time subsequent to the fourth period of time, causing the temperatureof both the first side and the second side of the electronic device tobe heated substantially above 25 degrees Celsius, and performing afunctional electronic test of the integrated circuit at this elevatedtemperature.

Some embodiments of the method further include repeatedly cycling apolarity of a thermal stratification profile of an integrated circuitpackage on the electronic device between a first direction and anopposite second direction, during an eighth period of time subsequent tothe cycling, causing both the first side and the second side of theelectronic device to be at a room temperature of approximately 25degrees Celsius, and performing a functional electronic test of anintegrated circuit on the electronic device at this room temperature,during a ninth period of time subsequent to the cycling, causing of boththe first side and the second side of the electronic device to be cooledto an lowered temperature substantially below 25 degrees Celsius, andperforming a functional electronic test of the integrated circuit atthis lowered temperature, and during a tenth period of time subsequentto the cycling, causing both the first side and the second side of theelectronic device to be heated to an elevated temperature substantiallyabove 25 degrees Celsius, and performing a functional electronic test ofthe integrated circuit at this elevated temperature.

In some embodiments of the method, a magnitude of temperature differenceduring the cycling is approximately the difference between the elevatedtemperature and the lowered temperature. In some embodiments of themethod, a magnitude of temperature difference during the cycling issubstantially larger than the difference between the elevatedtemperature and the lowered temperature.

Some embodiments of the method further include, during an eleventhperiod of time subsequent to the cycling, causing first side of theelectronic device to be cooled to the lowered temperature substantiallybelow 25 degrees Celsius causing the second side of the electronicdevice to be heated to the elevated temperature substantially above 25degrees Celsius, and performing a functional electronic test of theintegrated circuit at this first differential temperature, and during atwelfth period of time subsequent to the cycling, causing second side ofthe electronic device to be cooled to the lowered temperaturesubstantially below 25 degrees Celsius causing the first side of theelectronic device to be heated to the elevated temperature substantiallyabove 25 degrees Celsius, and performing a functional electronic test ofthe integrated circuit at this second differential temperature.

Another aspect of some embodiments include an apparatus that includes acontroller, temperature stratification means as described above,operatively coupled to the controller, for repeatedly cycling atemperature profile across an electronic device between two directions.In some embodiments, the temperature stratification means includes afluid circulation chamber means for turbulently flowing a heat-exchangefluid in contact with an integrated circuit on the electronic device. Insome embodiments, the temperature stratification means includes aheat-transfer surface means for contacting and conducting heat to anintegrated circuit on the electronic device.

It is understood that the above description is intended to beillustrative, and not restrictive. Many other embodiments will beapparent to those of skill in the art upon reviewing the abovedescription. The scope of the invention should be, therefore, determinedwith reference to the appended claims, along with the full scope ofequivalents to which such claims are entitled.

1. An apparatus comprising: a first heat-transfer device for changing atemperature of a first surface of an electronic device; a secondheat-transfer device for changing a temperature of a second surface ofthe electronic device opposite the first surface; and a controlleroperatively coupled to the first heat-transfer device and to the secondheat-transfer device and operable during a first period of time to causethe first heat-transfer device to raise the temperature of the firstsurface and the second heat-transfer device to lower the temperature ofthe second surface to a level below the temperature of the firstsurface; and operable during a second period of time to cause the firstheat-transfer device to lower the temperature of the first surface andthe second heat-transfer device to raise the temperature of the secondsurface to a level above the temperature of the first surface of theelectronic device.
 2. The apparatus of claim 1, further comprising oneor more information-processing systems that collect testing results fromthe electronic device after the second period of time, and based on thetesting results, sort the electronic device as good or faulty.
 3. Theapparatus of claim 1, wherein the first heat-transfer device includes achamber that substantially surrounds the first surface of the electronicdevice and circulates a heated fluid against the first surface of theelectronic device during the first period of time.
 4. The apparatus ofclaim 3, wherein the second heat-transfer device includes a chamber thatsubstantially surrounds the second surface of the electronic device andcirculates a cooled fluid against the second surface of the electronicdevice during the first period of time.
 5. The apparatus of claim 4,wherein the first surface includes substantially all of one side of aprinted circuit board, and the second surface includes substantially allof the opposite side of the printed circuit board.
 6. The apparatus ofclaim 4, wherein the first surface includes substantially all of oneside of a printed circuit board, and the second surface includes asubstantially smaller portion of the opposite side of the printedcircuit board corresponding to a single integrated circuit packagemounted on the electronic device.
 7. The apparatus of claim 3, whereinthe second heat-transfer device includes a thermally conductive surfacethat is pressed against the second surface of the electronic device andis cooled during the first period of time.
 8. The apparatus of claim 7,wherein the first surface includes substantially all of one side of aprinted circuit board, and the second surface includes substantially allof the opposite side of the printed circuit board.
 9. The apparatus ofclaim 7, wherein the first surface includes substantially all of oneside of a printed circuit board, and the second surface includes asubstantially smaller portion of the opposite side of the printedcircuit board corresponding to a single integrated circuit packagemounted on the electronic device.
 10. The apparatus of claim 1, whereinthe first heat-transfer device includes a thermally conductive surfacethat is pressed against the first surface of the electronic device andis heated during the first period of time.
 11. The apparatus of claim10, wherein the first heat-transfer device includes a Peltier device,and has a compliant material between the Peltier device and the firstsurface of the electronic device.
 12. The apparatus of claim 10, whereinthe second heat-transfer device includes a thermally conductive surfacethat is pressed against the second surface of the electronic device andis cooled during the first period of time.
 13. The apparatus of claim11, wherein the second heat-transfer device includes a Peltier device,and has a compliant material between the Peltier device and the secondsurface of the electronic device.
 14. The apparatus of claim 1, wherein:the first heat-transfer device includes a chamber that substantiallysurrounds the first surface of the electronic device and circulates aheated fluid against the first surface of the electronic device duringthe first period of time, the second heat-transfer device includes achamber that substantially surrounds the second surface of theelectronic device and circulates a cooled fluid against the secondsurface of the electronic device during the first period of time; thefirst surface includes substantially only a portion of one side of aprinted circuit board corresponding to a single integrated circuitpackage mounted on the electronic device; and the second surfaceincludes substantially only a portion of the opposite side of theprinted circuit board corresponding to the single integrated circuitpackage.
 15. An apparatus comprising: a first heat-transfer deviceincluding a first chamber that substantially surrounds a first surfaceof an electronic device to circulate a first fluid against the firstsurface of the electronic device to change a temperature of the firstsurface of the electronic device; a second heat-transfer device tochange a temperature of a second surface of the electronic deviceopposite the first surface; and a controller operatively coupled to thefirst heat-transfer device and to the second heat-transfer device andoperable during a first period of time to cause the first heat-transferdevice to raise the temperature of the first surface and the secondheat-transfer device to lower the temperature of the second surface to alevel below the temperature of the first surface; and operable during asecond period of time to cause the first heat-transfer device to lowerthe temperature of the first surface and the second heat-transfer deviceto raise the temperature of the second surface to a level above thetemperature of the first surface of the electronic device.
 16. Theapparatus of claim 15, wherein the first surface includes substantiallyall of one side of a printed circuit board, and the second surfaceincludes substantially all of an opposite side of the printed circuitboard.
 17. The apparatus of claim 15, wherein the first surface includessubstantially all of one side of a printed circuit board, and the secondsurface includes a substantially smaller portion of an opposite side ofthe printed circuit board corresponding to a single integrated circuitpackage mounted on the electronic device.
 18. The apparatus of claim 15,wherein the first fluid is to be heated or cooled by the firstheat-transfer device.
 19. The apparatus of claim 15, wherein: the firstsurface includes substantially only a portion of one side of a printedcircuit board corresponding to a single integrated circuit packagemounted on the electronic device; and the second surface includessubstantially only a portion of an opposite side of the printed circuitboard corresponding to the single integrated circuit package.
 20. Theapparatus of claim 15, wherein the electronic device comprises: aprinted circuit board; a flip-chip substrate; an electronic chip; afirst solder-ball interface to connect the printed circuit board toflip-chip substrate; and a second solder-ball interface to connect theflip-chip substrate to the electronic chip.
 21. The apparatus of claim15, wherein the first heat-transfer device includes a thermal forcingunit and a fan to force a turbulent flow of air or an inert fluid in thefirst chamber.
 22. The apparatus of claim 15, wherein the secondheat-transfer device includes a thermally conductive surface that ispressed against the second surface of the electronic device.
 23. Anapparatus comprising: a first heat-transfer device including a firstchamber that substantially surrounds a first surface of an electronicdevice to circulate a first fluid against the first surface of theelectronic device to change a temperature of the first surface of theelectronic device; a second heat-transfer device including a secondchamber that substantially surrounds a second surface of the electronicdevice opposite the first surface to circulate a second fluid againstthe second surface of the electronic device to change a temperature ofthe second surface of the electronic device; and a controlleroperatively coupled to the first heat-transfer device and to the secondheat-transfer device and operable during a first period of time to causethe first heat-transfer device to raise the temperature of the firstsurface and the second heat-transfer device to lower the temperature ofthe second surface to a level below the temperature of the firstsurface; and operable during a second period of time to cause the firstheat-transfer device to lower the temperature of the first surface andthe second heat-transfer device to raise the temperature of the secondsurface to a level above the temperature of the first surface of theelectronic device.
 24. The apparatus of claim 23, wherein the firstsurface includes substantially all of one side of a printed circuitboard, and the second surface includes substantially all of an oppositeside of the printed circuit board.
 25. The apparatus of claim 23,wherein the first surface includes substantially all of one side of aprinted circuit board, and the second surface includes a substantiallysmaller portion of an opposite side of the printed circuit boardcorresponding to a single integrated circuit package mounted on theelectronic device.
 26. The apparatus of claim 23, wherein: the firstfluid is to be heated or cooled by the first heat-transfer device; andthe second fluid is to be heated or cooled by the second heat-transferdevice.
 27. The apparatus of claim 23, wherein: the first surfaceincludes substantially only a portion of one side of a printed circuitboard corresponding to a single integrated circuit package mounted onthe electronic device; and the second surface includes substantiallyonly a portion of an opposite side of the printed circuit boardcorresponding to the single integrated circuit package.
 28. Theapparatus of claim 23, wherein the electronic device comprises: aprinted circuit board; a flip-chip substrate; an electronic chip; afirst solder-ball interface to connect the printed circuit board toflip-chip substrate; and a second solder-ball interface to connect theflip-chip substrate to the electronic chip.
 29. The apparatus of claim23, wherein: the first heat-transfer device includes a thermal forcingunit and a fan to force a turbulent flow of air or an inert fluid in thefirst chamber; and the second heat-transfer device includes a thermalforcing unit and a fan to force a turbulent flow of air or an inertfluid in the second chamber.
 30. The apparatus of claim 23, furthercomprising: a third heat-transfer device including a third chamber thatsubstantially surrounds a third surface of the electronic deviceadjacent to the first surface to circulate a third fluid against thethird surface of the electronic device to change a temperature of thethird surface of the electronic device; a first dividing wall betweenthe first chamber and the third chamber; a fourth heat-transfer deviceincluding a fourth chamber that substantially surrounds a fourth surfaceof the electronic device opposite the third surface and adjacent to thesecond surface to circulate a fourth fluid against the fourth surface ofthe electronic device to change a temperature of the fourth surface ofthe electronic device; and a second dividing wall between the secondchamber and the fourth chamber.